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Maintenance
CHANGING WIRE SIZES
This welder is setup for .035 (.9mm)
wire. If a different wire size is used, the
wire feed drive roll and contact tip may
need changing. There are two grooves
in the drive roll. The small groove is for
.023 (.6mm) wire and the other is for
.030-.035 (.8-.9mm) wire. Remove the
roller cover and flip the drive roll to
choose the correct groove (See parts
breakdown). The contact tip should
also match the wire diameter used. The
tip diameter is marked on the contact
tip in inches or millimeters. For
aluminum wire, oversize contact tip
one size (Ex. - Use .035" tip for .030"
diameter wire).
Welding Guidelines
General
This line of welding machines can utilize
the Flux Cored Arc Welding (Gasless)
process or the Gas Metal Arc Welding
(MIG) process. The weld must be
protected (shielded) from contaminates
in the air while it is molten. The gasless
process uses a tubular wire with a flux
material inside. The flux creates a
shielding gas when melted. The MIG
process uses inert gas to shield the weld
while molten.
When current is produced by a
transformer (welding machine) and flows
through the circuit to the weld wire, an
arc is formed between the end of the
Nozzle
Shielding
Gas
Slag
Weld
Crater
Work Piece
Figure 9 - Weld Components
(Con't.)
Supply Cable Replacement
1. Verify that welder is OFF and power cord disconnected.
2. Remove welder cover to expose the ON/OFF switch.
3. Disconnect the black and white power cord wires connected to the ON/OFF
switch.
4. Disconnect the green power cord wire connected to welder frame.
5. Loosen the cord strain relief screw(s) and pull cord out of strain relief.
6. Install new cord in reverse order.
weld wire and the work piece. This arc
melts the wire and the work piece. The
melted metal of the weld wire flows into
the molten crater and forms a bond with
the work piece as shown (Figure 9).
Arc Welding Basics
Five basic techniques affect weld quality.
These are: wire selection, heat setting,
weld angle, wire speed, and travel speed.
An understanding of these techniques is
necessary for effective welds.
HEAT SETTING
The correct heat involves the adjustment
of the welding machine to the required
setting. Heat or voltage is regulated by a
switch on the welder. The heat setting
Contact
used depends on the size (diameter) and
Tip
type of wire, position of the weld, and
Flux
the thickness of the work piece. Consult
(Gasless
only)
specifications listed on the welder. It is
suggested that the welder practice with
Wire
scrap metal to adjust settings, and
compare welds with Figure 11.
WIRE TYPE AND SIZE
The correct choice of wire type involves
a variety of factors, such as welding
position, work piece material type,
thickness, and condition of surface to
be welded. The American Welding
Society, AWS, has set up certain
requirements for each type of wire.
FLUX-CORED WIRE
E - 7 0 T - GS
AWS E71T-GS or E71T-11 is
recommended for this welder.
SOLID WIRE
ER - 70 S - 6
ER-70S6 is recommended for this
welder.
7
Model WG2020
Weld strength, times
10,000 pounds per
square inch
Welding positions (0
for flat or horizontal,
1 for any position)
Tubular flux core wire
Flux type
Weld strength, times
1,000 PSI
Solid wire
Wire composition
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